Dual Engine Controller Cross-Talk for FADEC Failure Recovery
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Solution Overview
Problem
Aircraft with automatic engine control systems face operational challenges when a Full Authority Digital Engine Control (FADEC) system fails, leading to loss of dynamic control and increased pilot workload, especially in situations where manually operated backup systems are not available, resulting in diminished engine power and maneuverability.
Innovation Solution
A system and method that allows dynamic control of a first gas turbine engine by a second engine controller when the primary engine controller is malfunctioning, enabling continued operator input and control through a dual-engine controller configuration, allowing for seamless switching and dynamic adjustment of engine power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a manually operated backup system is included, then reliability is improved, but device complexity and weight increase
Solution Approach 1:
The patent merges the backup control functionality into the existing digital engine controller by implementing a cross-talk feature that allows one engine controller to take over control of another engine when its primary controller fails. This eliminates the need for separate manual backup systems while maintaining reliability.
Solution Approach 2:
The digital engine controller is designed to perform multiple functions: it controls its own associated engine under normal conditions, and can also control another engine's components when that engine's primary controller fails. This multi-functionality removes the need for dedicated backup hardware.
2Reliability
If conventional systems shut down affected engines upon FADEC failure, then reliability is maintained, but productivity deteriorates
Solution Approach 1:
The patent introduces a cross-talk communication mechanism as an intermediary between engine controllers. When one controller fails, the other controller uses this communication channel to take over control, allowing the affected engine to remain operational rather than being shut down.
Solution Approach 2:
The control system dynamically adapts its configuration based on operational conditions. Under normal conditions, each controller independently controls its own engine. Upon failure detection, the system dynamically reconfigures to allow cross-control, maintaining engine operation without shutdown.
3Ease of operation
If predetermined operating mode is used upon FADEC failure, then ease of operation is improved, but adaptability deteriorates
Solution Approach 1:
The system continuously monitors controller health status and automatically triggers cross-talk control when failure is detected. This feedback mechanism allows the system to maintain full adaptability by dynamically switching control modes based on real-time conditions, rather than being locked into a predetermined operating mode.
Data Source
AI summary
In one aspect, a method for dynamically controlling the operation of an aircraft having a first gas turbine engine and a second gas turbine engine may generally include receiving, by a first engine controller and a second engine controller, one or more operator commands deriving from an operator manipulated input device. The method may also include controlling the operation of the first gas turbine engine via the first engine controller, and the second gas turbine engine via the second engine controller. In addition, the method may include detecting a fault condition associated with the first engine controller, and subsequently switching control of the first gas turbine engine from the first engine controller to the second engine controller. The method may further include dynamically controlling the operation of the first gas turbine engine with the second engine controller.